So I was finally able to find a workaround for these larger than 2 Gb files getting corrupted. This fix results in an MP4 file that includes video & audio. This process requires a program to handle a .zip file (built into newer versions of windows) AND requires VLC Media Player which can be downloaded for free from videolan.org.
1. First, make a copy of your .replay file you want to fix so you don't damage the original file further
2. Rename the .replay file to .zip
3. Open the .zip file and navigate to replay -> media
4. Copy out the .bin files you find inside of there to a new folder
5. Rename the .bin file to .avi
6. Open VLC Media Player and go to Tools -> Preferences -> Input / Codecs
7. About the fourth section down is "Files" and you'll see a section that says "Damaged or Incomplete AVI File". Change this setting to "Always Fix" and click Save
8. Open the new AVI files you created in step 5
9. From here you can convert these files to mp4 by using "Convert/Save" under Media
- Click add in the File Window and select your AVI files
- Then at the bottom click the arrow next to "Convert/Save" and select "Convert"
- From here you'll want to select a conversion profile in the dropdown list. I selected the first option "Video - H.264 + MP3 (MP4)" and made some modifications.
- To modify select the little gear icon, then jump to the Audio Codec tab, then change it to MP3 and change the bitrate to 320/kbps
- From here you'll click browse at the bottom of the window to name your file. The file type should be mp4 and I removed the .avi from the default file name
- At this point, you can hit start. You'll see this window minimize and the player window appears (if not just click the VLC Player icon in the taskbar). You can watch the conversion progress by following the time progressed in the bottom left of the player. When it gets to the end and the timer disappears the conversion is done.
- Congratulations! You can now find your converted MP4 file with audio and video in the location you chose to save it.
I hope this helps everyone!!